Display device

ABSTRACT

A method of manufacturing a display device, including: a stacking step of stacking, on a glass substrate, a sacrificial resin layer, a metal layer, a transparent metal oxide layer, a base material resin layer, and a functional layer including at least one of a pixel circuit-constituting layer driving a plurality of pixels and a color filter layer, in this order; a radiating step of radiating a pulsed light of a xenon flash lamp to the metal layer through the glass substrate and the sacrificial resin layer; and a detaching step of reducing a force of adhesion between the sacrificial resin layer and the metal layer with the pulsed light radiated in the radiating step, and detaching the sacrificial resin layer from the metal layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/831,452 filed on Dec. 5, 2017, which, in turn, is a continuation ofU.S. patent application Ser. No. 15/246,707 (now U.S. Pat. No.9,865,817) filed on Aug. 25, 2016. Further, this application claimspriority from Japanese application JP2015-182983 filed on Sep. 16, 2015,the entire contents of which are hereby incorporated by reference intothis application.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a method of manufacturing a displaydevice, and a display device.

2. Description of the Related Art

Flexible displays allowing a display screen to be flexibly deformed areknown.

In manufacturing the flexible display, a resin material such aspolyimide is first deposited on a support substrate of glass or thelike, and a functional layer in which thin film transistors or colorfilters are arranged is formed on the resin material. Thereafter, a stepof detaching the resin material from the substrate is provided.

In JP 2013-145808 A, it is described to provide a method of detaching asubstrate, which is low in cost and has high productivity.

Here, as a technique for detaching the resin material from the supportsubstrate, radiating a laser to the rear surface of the resin materialto ablate the resin material is known. However, using the laserincreases a device cost and decreases throughput, making it difficult torealize efficient mass production.

It is also conceivable that a metal layer as a heat exchange membrane isformed between the glass substrate and the resin layer, light of a flashlamp is radiated from the glass substrate side to thermally decomposeinstantaneously the resin located at the interface of the metal layer,and the resin layer is detached from the glass substrate.

In the method using the flash lamp, however, while heat is easilygenerated at the interface between the glass substrate and the metallayer, the heat generated is less likely to be conducted to the resinlayer and thus the resin located at the interface of the metal layer maynot be thermally decomposed sufficiently.

Moreover, it is also conceivable to facilitate the heat conduction tothe resin layer by thinning the metal layer. However, the thinned metallayer allows the light emitted by the flash lamp to reach the functionallayer located on the resin layer, so that the functional layer may bedestroyed.

SUMMARY OF THE INVENTION

In view of the problems described above, it is an object of theinvention to provide a method of efficiently detaching a resin layer, onwhich a functional layer such as a color filter layer or a thin filmtransistor layer is formed, from a support substrate in manufacturing adisplay device and a flexible display. Moreover, it is an object of theinvention to provide a display device in which a detaching method inmanufacturing a display device and a flexible display is made efficient.

In view of the problems described above, a method of manufacturing adisplay device according to an aspect of the invention includes: astacking step of stacking, on a glass substrate, a sacrificial resinlayer, a metal layer, a transparent metal oxide layer, a base materialresin layer, and a functional layer including at least one of a pixelcircuit-constituting layer driving a plurality of pixels and a colorfilter layer, in this order; a radiating step of radiating a pulsedlight of a xenon flash lamp to the metal layer through the glasssubstrate and the sacrificial resin layer; and a detaching step ofreducing a force of adhesion between the sacrificial resin layer and themetal layer with the pulsed light radiated in the radiating step, anddetaching the sacrificial resin layer from the metal layer.

In view of the problems described above, a display device according toanother aspect of the invention includes: a first protective film; ametal layer stacked on the first protective film; a first transparentmetal oxide layer stacked on the metal layer; a first base materialresin layer stacked on the first transparent metal oxide layer; and apixel circuit-constituting layer including a plurality of pixel circuitsstacked on the first base material resin layer and controllingluminances for displaying an image.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a display device according to a firstembodiment.

FIG. 2 is a schematic view showing a pixel circuit of the display devicein the first embodiment.

FIG. 3A is a diagram showing a cross-section of the display device inthe first embodiment, in a state before detaching resin layers fromsupport substrates.

FIG. 3B is a diagram showing a cross-section of the display device inthe first embodiment, in a state after detaching the resin layers fromthe support substrates.

FIGS. 4A to 4C are diagrams for explaining a manufacturing step of thedisplay device in the first embodiment.

FIGS. 5A to 5C are diagrams for explaining a manufacturing step of thedisplay device in the first embodiment.

FIGS. 6A to 6F are diagrams for explaining a manufacturing step of thedisplay device in the first embodiment.

FIGS. 7A to 7D are diagrams for explaining a manufacturing step of thedisplay device in the first embodiment.

FIG. 8A is a diagram showing a cross-section of a display device in asecond embodiment, in a state before detaching resin layers from supportsubstrates.

FIG. 8B is a diagram showing a cross-section of the display device inthe second embodiment, in a state after detaching the resin layers fromthe support substrates.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, a display device according to each embodiment of theinvention will be described with reference to the drawings.

First Embodiment

FIG. 1 is a schematic perspective view for explaining a display deviceof a first embodiment using an organic EL display device as an example.

An organic EL display device 1 of the embodiment includes a first basematerial resin layer B1 on which a plurality of light-emitting elements(organic electroluminescence elements) are disposed, and a second basematerial resin layer B2 bonded to the first base material resin layerB1. The organic EL display device 1 includes a display area DP, and theplurality of light-emitting elements are located in the display area DP.A major surface of the first base material resin layer B1 facing thesecond base material resin layer B2 includes an area not covered by thesecond base material resin layer B2, that is, an exposed area (exposedarea EX). A flexible printed board F1 is disposed in the exposed areaEX.

FIG. 2 is a diagram showing a pixel circuit in the display area DP ofthe organic EL display device 1 of the first embodiment. The organic ELdisplay device 1 includes the display area DP where an image isdisplayed, a scanning signal line drive unit GDR, a video signal linedrive unit DDR, and a power source drive unit EDR.

In the display area DP, a plurality of pixel circuits PX that controlluminances for displaying an image are disposed in a matrix. Moreover,an organic electroluminescence element OL (light-emitting element) isdisposed corresponding to each of pixels. The pixel circuit PX includesa thin film transistor TFT1, a capacitive element CAP, and a thin filmtransistor TFT2. The scanning signal line drive unit GDR, the videosignal line drive unit DDR, and the power source drive unit EDR drivethe pixel circuits PX to control the emission of the organicelectroluminescence elements OL.

The scanning signal line drive unit GDR is connected to scanning signallines GL each provided for an array of pixels (pixel row) in thehorizontal direction, and outputs a scanning signal to the scanningsignal lines GL sequentially selected.

The video signal line drive unit DDR is connected to video signal linesDL each provided for an array of pixels (pixel column) in the verticaldirection, and outputs, in synchronization with the selection of thescanning signal line GL by the scanning signal line drive portion GDR, avoltage in response to a video signal of the selected pixel row to eachof the video signal lines DL. The voltage is written to the capacitiveelement CAP in the pixel circuit PX, and a current in response to thewritten voltage is supplied to the organic electroluminescence elementOL.

The power source drive unit EDR is connected to drive power source linesSL each provided for the pixel column, and supplies a current to theorganic electroluminescence element OL through the thin film transistorTFT2 in the pixel circuit PX.

A cathode of the organic electroluminescence element OL is connected toa ground potential, and the cathodes of the organic electroluminescenceelements OL of all of the pixels are configured of a common electrode.

FIG. 3A is a schematic view showing cross-sections of support substrates(glass substrates) SB1 and SB2 above which the base material resinlayers B1 and B2 are respectively disposed, that is, cross-sections in astate before detaching the base material resin layers B1 and B2. FIG. 3Bis a cross-sectional schematic view showing a state after detaching thebase material resin layers B1 and B2 from the support substrates SB1 andSB2, that is, the state of a flexible display (the organic EL displaydevice 1).

In the flexible display, since the base material resin layer B1 on whichthe pixel circuits PX are formed in a matrix, and the base materialresin layer B2 on which a color filter layer CF is formed, have a lowrigidity, a step of forming a functional layer on the resin layersusing, as bases, the support substrates SB1 and SB2 formed of a materialsuch as glass is implemented.

In the embodiment as shown in FIG. 3A, a first sacrificial resin layerSC1, a first metal layer M1, a first transparent metal oxide layer TR1,and the first base material resin layer B1 are formed on the firstsupport substrate SB1. A second sacrificial resin layer SC2, a secondmetal layer M2, a second transparent metal oxide layer TR2, and thesecond base material resin layer B2 are formed on the second supportsubstrate SB2. A pixel circuit-constituting layer CL including theplurality of pixel circuits PX is disposed on the first base materialresin layer B1. The color filter layer CF and a black matrix BM aredisposed on the second base material resin layer B2. Moreover, a notch(groove) for providing the exposed area EX is formed in each of thelayers formed on the second support substrate SB2 as shown in FIG. 3A.

As shown in FIG. 3A, a first protective layer PR1 and a secondprotective layer PR2 are formed on the first base material resin layerB1 and the second base material resin layer B2, respectively. A sealingmaterial SL and a filling material FL are located between the firstprotective layer PR1 and the second protective layer PR2. The first basematerial resin layer B1 and the second base material resin layer B2 arebonded together through the sealing material SL and the filling materialFL. At the stage of FIG. 3A, a terminal TE on the surface of which atransparent conductive film TR is formed is disposed in the exposed areaEX, in the state of being covered by the first protective layer PR1.

Each of the first base material resin layer B1, the second base materialresin layer B2, the first sacrificial resin layer SC1, and the secondsacrificial resin layer SC2 is formed of, for example, a resincontaining polyimide as a material. The first metal layer M1 and thesecond metal layer M2 are formed of, for example, Ti, Mo, or W(titanium, molybdenum, or tungsten) having a high melting point. Thefirst base material resin layer B1 and the second base material resinlayer B2 serving as base material layers of the flexible display areconfigured to have a thickness of approximately 10 μm (specifically, athickness of 5 μm or more and 20 μm or less). The first and second metallayers M1 and M2 prevent a flash caused by a flash lamp described laterfrom transmitting to the functional layer. Therefore, the first andsecond metal layers M1 and M2 are configured to have a thickness of atleast approximately 100 nm (specifically, a thickness of 75 nm or moreand 200 nm or less). The first transparent metal oxide layer TR1 and thesecond transparent metal oxide layer TR2 are layers for improvingadhesion between the first metal layer M1 and the first base materialresin layer B1 and adhesion between the second metal layer M2 and thesecond base material resin layer B2, and are formed of, for example,indium tin oxide (ITO) with a thickness of approximately 5 nm(specifically, a thickness of 3 nm or more and 20 nm or less). The firstsacrificial resin layer SC1 and the second sacrificial resin layer SC2are formed to a thickness of approximately 1 μm.

In the final state of the flexible display in the embodiment as shown inFIG. 3B, the support substrates SB1 and SB2 on both sides, thesacrificial resin layers SC1 and SC2 on both sides, and the second metallayer M2 on the side where the color filter layer CF is present areremoved. Further, the protective films PT1 and PT2 are respectivelyattached to an outermost surface on the side of the first base materialresin layer B1 and an outermost surface on the side of the second basematerial resin layer B2.

With reference to FIGS. 4A to 7D, a method of detaching the first basematerial resin layer B1 and the second base material resin layer B2 fromthe first support substrate SB1 and the second support substrate SB2 inthe embodiment will be described in further detail below.

FIGS. 4A to 4C are diagrams for explaining a manufacturing step of theorganic EL display device 1 in the embodiment, explaining a step ofpreparing a structure including the first and second support substratesSB1 and SB2, the first and second sacrificial resin layers SC1 and SC2,the first and second metal layers M1 and M2, the first and secondtransparent metal oxide layers TR1 and TR2, the first and second basematerial resin layers B1 and B2, and the functional layer (the colorfilter layer CF or the pixel circuit-constituting layer CL).

Specifically, as shown in FIG. 4A, the first sacrificial resin layer SC1is first stacked on the first support substrate SB1, and then, thesurface of the first sacrificial resin layer SC1 is subjected to aplasma treatment for modification. Thereafter, as shown in FIG. 4B, thefirst metal layer M1 is formed on the first sacrificial resin layer SC1subjected to the plasma treatment. Further, as shown in FIG. 4C, thefirst transparent metal oxide layer TR1, the first base material resinlayer B1, the pixel circuit-constituting layer CL, and the firstprotective layer PR1 are formed in this order to form a pixel circuitstructure including the pixel circuit-constituting layer. As shown inFIG. 4C, the pixel circuit-constituting layer CL is covered by the firstprotective layer PR1.

Since the plasma treatment is performed in FIG. 4A, the adhesion betweenthe first sacrificial resin layer SC1 containing polyimide as a materialand the first metal layer M1 is improved, making it possible to advancesubsequent manufacturing steps without problems. Similarly, also for astructure including the color filter layer CF as a functional layer, thesurface of the second sacrificial resin layer SC2 is subjected to aplasma treatment to improve adhesion between the second sacrificialresin layer SC2 and the second metal layer M2.

In a common manufacturing process, a plurality of organic EL displaydevices 1 or the layers included in the organic EL display device 1 areformed on a mother glass substrate, and then, the mother glass substrateis cut into individual organic EL display devices 1. FIGS. 5A to 5C arediagrams for explaining a manufacturing step of the organic EL displaydevice 1 in the embodiment, explaining the state where a pair of motherglass substrates, on which the layers included in the organic EL displaydevice 1 are formed and which are bonded together, are cut intoindividual organic EL display devices 1.

As shown in FIG. 5A, in the manufacturing step of the embodiment, thefirst support substrate SB1, in other words, the mother glass substrateon the side of the first support substrate SB1 is first cut bysandblasting. Then, as shown in FIG. 5B, the pair of mother glasssubstrates are inverted, and the second support substrate SB2, in otherwords, the mother glass substrate on the side of the second supportsubstrate SB2 is cut. Thereafter, as shown in FIG. 5C, the mother glasssubstrate on the side of the second support substrate SB2 is scribed atthe position overlapping the notch (groove) for providing the exposedarea EX, and the second support substrate SB2 at the position facing theexposed area EX is cut off.

Here, especially FIGS. 6A to 6F are diagrams for explaining a step ofdetaching the second support substrate SB2 on the color filter layer CFside from the second base material resin layer B2.

As shown in FIG. 6A, in the step of detaching the second supportsubstrate SB2 from the second base material resin layer B2 containingpolyimide as a material, a pulsed light of a xenon flash lamp at awavelength of from 200 to 1100 nm is first radiated from the secondsupport substrate SB2 side. The radiation time of the xenon flash lampis approximately from 1 μs to several ms, and the intensity of the xenonflash lamp is from several mJ/cm² to several tens mJ/cm². At this time,a light-shielding mask SH is disposed for the exposed area EX so thatthe light of the flash lamp is not radiated to the exposed area EX.

Thereafter, as shown in FIG. 6B, when the pulsed light caused by thexenon flash lamp is radiated so as to reach the second metal layer M2through the second support substrate SB2 and the second sacrificialresin layer SC2, the pulsed light is absorbed by the second metal layerM2 and generates heat. The heat generated by the pulsed light isinstantaneously conducted from the second metal layer M2 to the secondsacrificial resin layer SC2, and as shown in FIG. 6C, the polyimide atthe interface of the second sacrificial resin layer SC2 is thermallydecomposed, resulting in detachment of the second support substrate SB2and the second sacrificial resin layer SC2. The radiation time orintensity of the xenon flash lamp is adjusted such that the polyimide ofthe second sacrificial resin layer SC2 is heated to a temperature(approximately from 600 to 1200° C.) at which the polyimide is thermallydecomposed.

Next, as shown in FIG. 6D, the second metal layer M2 formed outside thecolor filter layer CF is removed by dry etching using fluorine radicals.The second metal layer M2 is removed in order to allow the light of thelight-emitting element to exit from the second support substrate SB2side. In this step of FIG. 6D, the first protective layer PR1 formed of,for example, a silicon nitride film or a silicon oxide film issimultaneously etched in the exposed area EX. Through the etching, theterminal TE located in the exposed area EX is exposed. The secondtransparent metal oxide layer TR2 and the transparent conductive film TRfunction as etching stopper films in this dry etching.

Thereafter, as shown in FIG. 6E, the protective film PT2 is disposed onthe second transparent metal oxide layer TR2, and as shown in FIG. 6F,the flexible printed board F1 is connected at the terminal TE in theexposed area EX.

FIGS. 7A to 7D are diagrams for explaining a step of detaching the firstsupport substrate SB1 from the first base material resin layer B1 onwhich the pixel circuits PX including thin film transistors made oflow-temperature polysilicon (LTPS) are formed.

As shown in FIG. 7A, in the step of detaching the first supportsubstrate SB1 from the first base material resin layer B1 containingpolyimide as a material, the light of the xenon flash lamp is firstradiated similarly to that in FIG. 6A. Thereafter, as shown in FIGS. 7Band 7C, heat is instantaneously conducted from the first metal layer M1to the first sacrificial resin layer SC1, and the polyimide at theinterface is thermally decomposed, resulting in detachment of the firstsupport substrate SB1 and the first sacrificial resin layer SC1.

After the step of FIG. 7C, the protective film PT1 is attached to therear surface of the first metal layer M1 as shown in FIG. 7D.

As shown in FIGS. 7D and 3B, the first metal layer M1 is left on therear side of the first base material resin layer B1 including the pixelcircuit-constituting layer, so that an electromagnetic wave, which mayaffect the functional layer including the pixel circuit PX, can beblocked. Moreover, the first transparent metal oxide layer TR1 isdisposed between the first metal layer M1 and the first base materialresin layer B1, improving the adhesion between the first base materialresin layer B1 formed of polyimide and the first metal layer M1. Thefirst transparent metal oxide layer TR1 is formed in this manner, sothat also in the flexible display in which the functional layer isformed on the base material resin layer, a structure that blocks anelectromagnetic wave can be stably formed on the base material resinlayer.

In the embodiment, the organic EL display device 1 including an organicelectroluminescence element has been described as an example of adisplay device. However, the display device may be a self-emittingdisplay device including a light-emitting element such as a quantum-dotlight-emitting element (quantum-dot light-emitting diode (QLED)) in eachof pixels. Moreover, the invention is not limited to the self-emittingdisplay device, and may also be applied to, for example, a flexibledisplay such as a liquid crystal display device.

In the embodiment, the detaching method in which the metal layer and thesacrificial resin layer are disposed and which uses a flash lamp is usedfor both the base material resin layer including the color filter layerand the base material resin layer including the pixelcircuit-constituting layer CL. However, the invention is not limited tosuch an aspect, and the detaching method may be used only for any one ofthe base material resin layers. Moreover, the base material resin layeron the counter substrate side where the pixel circuit-constituting layeris not provided may not necessarily include the color filter layer CF.For example, the pixels may only be partitioned by the black matrix BM,or a circular polarizer or a touch panel may be provided instead of thecolor filter layer CF. Especially in an organic EL display deviceincluding an organic electroluminescence element, the color filter layeris unnecessary when an organic light-emitting layer is colored inseparate three colors of red, yellow, and blue. Therefore, it ispreferred to use a circular polarizer or a touch panel as a countersubstrate.

Second Embodiment

FIGS. 8A and 8B are diagrams for explaining a second embodiment. In theembodiment, differences from the first embodiment will be described.Portions corresponding to those of the first embodiment are given thesame reference numerals and signs. An organic EL display device shown inFIG. 8B further includes a third transparent metal oxide layer TR3disposed between the first metal layer M1 and the first protective filmPT1, compared with the first embodiment.

As shown in FIG. 8A, which shows the organic EL display device duringits manufacture, the third transparent metal oxide layer TR3 is formedafter forming the first sacrificial resin layer SC1 and before formingthe first metal layer M1. The third transparent metal oxide layer TR3enhances the adhesion between the first sacrificial resin layer SC1 andthe first metal layer M1. This makes it possible to prevent thedetachment of the first metal layer M1 from the first sacrificial resinlayer SC1 during the manufacturing step. Further, a fourth transparentmetal oxide layer TR4 is formed after forming the second sacrificialresin layer SC2 and before forming the second metal layer M2.Thereafter, the fourth transparent metal oxide layer TR4 is removedafter detaching the second sacrificial resin layer SC2 and beforeremoving the second metal layer M2. Specifically, the process shown inFIGS. 6C and 6D is applied. The fourth transparent metal oxide layer TR4enhances the adhesion between the second sacrificial resin layer SC2 andthe second metal layer M2. This makes it possible to prevent thedetachment of the second metal layer M2 from the second sacrificialresin layer SC2 during the manufacturing step.

While there have been described what are at present considered to becertain embodiments of the invention, it will be understood that variousmodifications may be made thereto, and it is intended that the appendedclaims cover all such modifications as fall within the true spirit andscope of the invention.

What is claimed is:
 1. A display device comprising: a first protectivefilm; a first metal layer on the first protective film; a second metallayer on the first metal layer; a first base material resin layer on thesecond metal layer; and pixels with pixel circuits on the first basematerial resin layer, wherein a thickness of the first metal layer isgreater than a thickness of the second metal layer.
 2. The displaydevice according to claim 1, wherein the second metal layer is a metaloxide layer.
 3. The display device according to claim 1, wherein thesecond metal layer is transparent.
 4. The display device according toclaim 1, further comprising: a functional layer on the pixels; a thirdmetal layer located on the functional layer; a second base materialresin layer located on the third metal layer; and a second protectivefilm located on the second base material resin layer.
 5. The displaydevice according to claim 1, further comprising a third metal layerbetween the first protective film and the first metal layer.
 6. Thedisplay device according to claim 1, wherein the first metal layerincludes one of titanium, molybdenum, and tungsten.
 7. The displaydevice according to claim 1, wherein a thickness of the first metallayer is 75 nm or more and 200 nm or less.
 8. The display deviceaccording to claim 1, further comprising a second protective film on anopposite side of the pixels from the first base material resin layer. 9.The display device according to claim 1, further comprising a circularpolarizer on an opposite side of the pixels from the first base materialresin layer.
 10. The display device according to claim 1, furthercomprising a touch panel on an opposite side of the pixels from thefirst base material resin layer.
 11. A display device comprising: afirst protective film; a first metal layer on the first protective film;a second metal layer on the first metal layer; a resin layer on thesecond metal layer; and thin film transistors on the resin layer,wherein a thickness of the first metal layer is greater than a thicknessof the second metal layer.
 12. The display device according to claim 11,wherein the second metal layer is a metal oxide layer.
 13. The displaydevice according to claim 11, wherein the second metal layer istransparent.
 14. The display device according to claim 11, furthercomprising pixels including the film transistors on the resin layer. 15.The display device according to claim 11, wherein each of the pixels hasa light-emitting element.
 16. The display device according to claim 14,further comprising a circular polarizer on an opposite side of thepixels from the resin layer.
 17. The display device according to claim11, further comprising a third metal layer between the first protectivefilm and the first metal layer.
 18. The display device according toclaim 11, wherein the first metal layer includes one of titanium,molybdenum, and tungsten.
 19. The display device according to claim 11,wherein a thickness of the first metal layer is 75 nm or more and 200 nmor less.
 20. The display device according to claim 11, furthercomprising a second protective film on an opposite side of the resinlayer from the first protective film.